Troll Hunter Posted October 26, 2011 Share Posted October 26, 2011 My '91 defender is now suffering from door rot, and I urgently need to repair/replace the steel frames for both front doors. Only the top hinge on each front door is actually connected to anything, and the second row doors probably don't have long to live either. Has anybody tried replacing the original steel frames on Defender doors? I know that Land Rovers UK Ltd., and probably other specialists, offer door repair services, and YRM Metal Solutions can supply pre-formeed steel sections for rebuilds,but these options aren't a practical proposition from here, and getting the repair done locally, in a body shop, would cost far too many beer tokens. I've looked at the Technical Index, but there doesn't appear to be anything there that covers this repair. So, if any member has done this, or has some practical tips, eg on the need to anneal the skin, if required, then I'd be most grateful for their input. Many thanks, in advance, Mike Quote Link to comment Share on other sites More sharing options...
ejparrott Posted October 26, 2011 Share Posted October 26, 2011 Ashtree/Samara do galvanized frames with new skins, is that an option? Quote Link to comment Share on other sites More sharing options...
Troll Hunter Posted October 26, 2011 Author Share Posted October 26, 2011 Many thanks for your suggestion, but it's the same problem - I'm midway between Calgary and Vancouver. Mike Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted October 26, 2011 Share Posted October 26, 2011 Is this any use to you? http://www.repairmylandrover.co.uk/defender-repairguides/guide-to-defender-door-repair-internal-frame Quote Link to comment Share on other sites More sharing options...
Troll Hunter Posted October 26, 2011 Author Share Posted October 26, 2011 This looks like the genuine dog's bo!!ocks! Thank you very, very much, CwazyWabbit. This is a far more detailed guide than I had expected. Although I probably can't get the prefabricated metal sections out here, I can bend them from sheet and weld them up. This is a much better option than I had expected, and should be much cheaper, even if I have to buy a metal brake, than any others. I'll let you know how I get on. Mike Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted October 27, 2011 Share Posted October 27, 2011 No worries Mike It's not my work, belongs to user Repair My Landrover I just remembered it. Those top hat repair sections look simple enough to bend up, I look forward to seeing your work .... Take plenty of pictures for us! Quote Link to comment Share on other sites More sharing options...
Troll Hunter Posted October 28, 2011 Author Share Posted October 28, 2011 Will do. I orderd a sheet metal bending brake today, delivery some time next week. Any recommendation on sheet metal thickness I should use, please? The brake capacity is 17gauge, which equates to 1/20th inch, in Christian units, or approximately 1.25mm. This seems fairly substantial, and should be more than enough, but should I use something lighter? Mike Quote Link to comment Share on other sites More sharing options...
ejparrott Posted October 28, 2011 Share Posted October 28, 2011 if you can, use 1.25mm, I would! Depends how much later work you want to do, if you're prepared to paint lots and keep on top of, you could use .75mm I'm sure, but if you don't keep the rust at bay, you'll be doing it again sooner! Quote Link to comment Share on other sites More sharing options...
puffin1 Posted October 28, 2011 Share Posted October 28, 2011 Great thread and just what i was looking for,it just might save me a small fortune as i have two front doors to do on my 1996 Def 90. Quote Link to comment Share on other sites More sharing options...
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